Cable trays are turned using prefabricated fittings, modular bends, or careful on-site modifications to maintain cable integrity and system safety.

Prefabricated Fittings

The most common and recommended method for turning cable trays is to use prefabricated fittings designed for the specific tray system. These include:

• Elbows: 90° or 45° horizontal and vertical elbows allow smooth directional changes without cutting or bending the tray itself.
• Tees and Crosses: For branching or intersecting runs.
• Reducers and Transitions: To change tray width or shape while turning. Using these fittings ensures structural integrity, prevents sharp bends that could damage cables, and complies with electrical codes .

Modular and Adjustable Bends

Some cable tray systems, especially modular ladder or perforated trays, offer adjustable or segmented bends. These allow installers to create custom angles by connecting multiple short sections at incremental angles. This method is useful when prefabricated elbows are unavailable or when a non-standard angle is required .

On-Site Modifications

In situations where prefabricated fittings cannot be used, trays can be cut and reassembled to achieve a turn:

• Cut the tray at the desired location using a band saw, circular saw, or angle grinder suitable for the tray material (steel, aluminum, or fiberglass) while following safety precautions .
• Reattach sections using bolts, brackets, or splice plates to form the desired angle.
• Deburr edges to prevent cable damage and ensure safe handling. This method requires careful planning to maintain load capacity and avoid sharp bends that could stress cables .

Safety Considerations

• Always wear Kevlar gloves, eye protection, and appropriate PPE when cutting or handling trays .
• Avoid using torches for bending, as heat can weaken the tray material .
• Ensure that any turn does not exceed the manufacturer's recommended bend radius, which protects cables from excessive stress .

Summary

Turning cable trays is best achieved using prefabricated elbows and fittings, or modular adjustable sections for custom angles. On-site cutting and reassembly is a secondary method but requires strict adherence to safety and structural guidelines. Proper planning ensures smooth cable routing, system integrity, and compliance with installation standards .